Switching a utility's fleet to electric drive: A guide to reducing TCO by 30%
Rising diesel prices and stricter CO2 regulations are putting pressure on the fleets of energy providers. Retrofitting the existing fleet to electric drive not only protects the budget but also secures the future of your specialized vehicles. Discover how you can reduce total operating costs (TCO) by over 30%.
The topic briefly and concisely
Converting existing transporter fleets to electric drive reduces total operating costs (TCO) by over 30% due to lower energy and maintenance costs.
Through the HEERO D2E conversion, expensive special constructions (value up to €50,000) are preserved, which promotes the circular economy approach and conserves capital.
With a proven WLTP range of up to 425 km, converted Sprinters meet the daily demands of energy suppliers and service technicians.
For energy suppliers, a reliable fleet of transporters is essential, but the pressure to decarbonize is steadily growing. The EU regulation 2019/631 significantly tightens CO2 limits from 2025, making the operation of diesel fleets increasingly uneconomical. At the same time, the vehicles are often equipped with expensive, indispensable special structures for daily service operations. Heero offers a pragmatic solution with the patented D2E conversion (Diesel-to-Electric): We electrify your proven Mercedes-Benz Sprinters while preserving your valuable structures. This approach, based on the principle of circular economy, allows for a quick, economical, and sustainable modernization of your fleet.
Economic and regulatory pressure: The dual challenge for fleet operators
Energy suppliers face the challenge of future-proofing their fleets while operating costs are skyrocketing. The CO2 tax and volatile diesel prices are driving up the cost per kilometer. At the same time, the EU is drastically tightening the CO2 fleet limits for light commercial vehicles starting in 2025, with a reduction obligation of 15% compared to the reference year 2021. This makes continued operation of a purely diesel fleet an expensive risk. Many companies underestimate that the penalties for non-compliance will significantly burden the TCO. Acquiring new electric transporters is often associated with long delivery times and the loss of expensive, years-optimized special construction units, whose lifespan often exceeds 15 years. Protecting these investments while simultaneously decarbonizing the fleet is the central task. Therefore, the transition must not only be ecological but, above all, economically intelligent.
Circular economy as a solution: preserving value through D2E retrofitting
Instead of prematurely scrapping proven vehicles with valuable bodies, the D2E conversion offers a resource-saving alternative. This process aligns with the principles of the circular economy by maximizing the lifespan of existing assets. During the conversion, the complete combustion-driven powertrain is replaced with a powerful electric drive, while the chassis and body are retained. This reduces the manufacturing effort required for a new vehicle and the associated CO2 emissions by around 70%. The greatest advantage is the preservation of the investment in special bodies, which often amount to up to €50,000 per vehicle. Converting a Sprinter with HEERO takes only about 10 working days. Here are the central advantages of this approach:
Preservation of expensive and proven special and shelf installations.
Avoidance of long delivery times for new vehicles.
Reduction of the CO2 footprint through continued use of the vehicle.
No retraining of employees on a new vehicle model is necessary.
Increase in payload by eliminating heavy diesel components.
This approach not only conserves the environment but also your budget and operational processes, as you can read under Sustainability Goals in Fleet Management. But how capable is a converted vehicle in the demanding everyday life of an energy supplier?
Performance and range: Practicality for daily use
The concerns about the practicality of e-transporters are widespread, but they are unfounded with Heero. Our converted Sprinters offer a performance that is on par with the diesel originals. With a power output of up to 180 kW (245 hp) and immediate torque availability, even fully loaded operations in challenging terrains are no problem. The decisive figure is the range: Our vehicles achieve a WLTP range of up to 425 km. This covers over 95% of all daily driving profiles for field service technicians. The battery packs are modular and can be configured according to the requirement profile to optimize the balance between range and payload. Compared to many new e-transporters, whose range often falls short of 300 km, we offer superior planning reliability. Learn more about the conversion of service vehicles for technicians. Next, we will look at the significant cost advantages.
TCO analysis: How retrofitting reduces total operating costs by over 30%
The decision to electrify is a strategic investment that must be worthwhile. A detailed analysis of the Total Cost of Ownership (TCO) shows the enormous savings potential of the retrofit. While the initial costs for the retrofit are incurred, ongoing expenses drop drastically. Studies show that the operating costs for electric trucks can be up to 60% lower than their diesel counterparts. Particularly, maintenance costs can reduce by up to 90%, as maintenance-intensive components such as exhaust systems, transmissions, and oil changes are eliminated. Energy costs per 100 km for an electric transporter are about €6-8, compared to €15-20 for a diesel. Thus, the investment in the retrofit often pays off within just 4 to 5 years. Here is an example approach to calculating your savings:
Determine your current annual costs for diesel, maintenance, insurance, and taxes per vehicle.
Compare these with the projected costs for electricity (based on your annual mileage), reduced maintenance, and lower taxes.
Consider government subsidies that can cover up to 80% of the additional costs.
Calculate the avoided costs by retaining your specialized superstructures.
A detailed analysis of total costs shows how quickly the break-even point is reached. However, retrofitting the vehicle is only part of the solution.
Holistic electrification: Optimally utilizing charging infrastructure and funding
A successful fleet conversion requires a well-thought-out charging infrastructure at the depot. HEERO supports you in the planning and implementation of tailor-made charging solutions that are aligned with your operational processes. This includes the analysis of grid connection capacity and the implementation of intelligent load management to avoid expensive load peaks. Another crucial factor is the use of subsidies. The federal program "Climate-Friendly Commercial Vehicles and Infrastructure" (KsNI) subsidizes the purchase of e-commercial vehicles and the construction of charging infrastructure with up to 80% of the additional investment expenses. We actively support you with the application process to secure the maximum funding amount for your project. By combining conversion, intelligent charging infrastructure, and subsidies, the electrification of your fleet becomes a highly profitable project. This not only avoids long delivery times but also creates a sustainable and economical foundation for the future. See for yourself how practical it is.
Conclusion: Your advantage with HEERO – Partnership for a future-proof fleet
The conversion of your transporter fleet to sustainable electric drive is not a cost factor but a strategic investment in the future viability of your company. With the HEERO D2E conversion, you benefit from a solution that intelligently combines economy and ecology. You reduce your operating costs by over 30%, meet upcoming CO2 requirements, and protect your valuable investments in special constructions. Our converted Sprinters offer the range and performance you need for demanding use as a utility provider. Heero is more than just a converter; we are your partner for holistic electrification. Experience the future of commercial vehicle fleets. Request your personal consultation now or book a free everyday test.
More useful links
National Control Center for Charging Infrastructure provides comprehensive information on commercial vehicles and charging infrastructure.
The Federal Ministry of Transport informs about climate protection in transport and alternative drives for commercial vehicles.
The Association of the Automotive Industry (VDA) provides information on the E-Car Center Germany.
Strategy& (PwC) publishes a press release on the breakthrough of electric trucks.
EnBW offers information on the charging infrastructure for electric trucks.
The House of Technology (HDT) publishes an article about electromobility and the future of commercial vehicles.
FAQ
Why should I retrofit my existing fleet instead of buying new electric vans?
Retrofitting is often more economical and sustainable. You keep your expensive special constructions, avoid long delivery times for new vehicles, and reduce the CO2 emissions that would be generated by the production of a new vehicle. Additionally, your operating costs decrease significantly.
For which vehicles does Heero offer retrofitting?
Heero specializes in the professional electrification of Mercedes-Benz Sprinter models. This focus allows for a standardized, high-quality, and efficient retrofit in just about 10 working days.
How long does it take to retrofit a van?
The actual conversion time of a vehicle from diesel to electric drive at Heero is approximately 10 working days. This way, you can quickly return your vehicles to operational use.
Does Heero also support the planning of charging infrastructure?
Yes, Heero offers comprehensive consulting, which also includes the design and planning of the appropriate charging infrastructure for your depot. We analyze your needs and develop an efficient charging solution including load management.
How does the retrofitting affect the payload of the vehicle?
In most cases, the payload remains the same or can even be slightly increased. The heavy diesel engine and transmission are replaced by lighter electronic components, which compensates for the weight of the battery.
Can I test a retrofitted van?
Yes, Heero offers potential customers the opportunity to test a retrofitted vehicle as part of a 'zero-cost everyday test'. This allows you to convince yourself of the performance and practicality.
